Method for separating a natural gas stream into a methane-enriched fraction and a fraction enriched in C2 and higher hydrocarbons

ABSTRACT

A process for purifying a feed gas including methane and heavy hydrocarbons, including: step a): cooling the feed gas in a heat exchanger; step b): introducing the resulting into a first phase separator to produce a liquid stream depleted in methane and enriched in heavy hydrocarbons and a gas stream; step c): separating the gas stream in a membrane from which a methane-enriched permeate stream and a partially condensed residue stream exit; step d): introducing the residue stream from step c) into a second phase separator vessel in order to produce a liquid stream and a gas stream; step e): introducing at least one portion of the gas stream resulting from step d) into a JT expansion means; and step f): heating at least one portion of the expanded stream in the heat exchanger used in step a) counter-current to the feed stream in order to cool the latter.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a 371 of International PCT Application PCT/FR2018/051876, filed Jul. 23, 2018, which claims priority to French Patent Application No. 1757155, filed Jul. 27, 2017, the entire contents of which are incorporated herein by reference.

BACKGROUND

The present invention relates to a process for purifying a gas containing hydrocarbons heavier than methane, for example natural gas or a gas associated with oil production or a flare gas or a gaseous effluent from a refinery.

Most conventional units used for extracting natural gas liquids (NGLs) or liquid petroleum gases (LPGs) are cryogenic units. These are generally expensive and consume a lot of electricity. Some alternative membrane technologies make it possible to concentrate the natural gas liquids on the residue (retentate) side of a membrane. The Applicant has, for example, developed a polymer fiber, resistant to the formation of liquids and selective with respect to methane compared to hydrocarbons containing more than two or more than three carbon atoms: light hydrocarbons (and hydrogen) permeate while the partial pressure of heavier hydrocarbons increases on the high pressure side (residue side of the membrane) thus resulting in partial or even complete condensation of the heavy hydrocarbons.

SUMMARY

The inventors of the present invention have developed a solution enabling the separation of a gas stream into a methane-enriched fraction and a fraction enriched in C2 and higher hydrocarbons, minimizing the losses of methane during this removal and while minimizing the costs involved in the deployment of processes of this type.

The subject of the present invention is a process for purifying a feed gas stream comprising methane, and hydrocarbons containing at least two carbon atoms, comprising the following steps:

-   -   Step a): cooling the feed gas stream in a heat exchanger;     -   Step b): introducing the stream resulting from step a) into a         first phase separator vessel in order to produce a liquid stream         depleted in methane and enriched in hydrocarbons containing more         than two carbon atoms and a gas stream;     -   Step c): separating the gas stream resulting from step b) in a         membrane permeation unit from which at least one         methane-enriched gaseous permeate stream and one partially         condensed residue stream enriched in hydrocarbons containing at         least two carbon atoms exit;     -   Step d): introducing the residue stream resulting from step c)         into a second phase separator vessel in order to produce at         least two phases including a liquid stream and a gas stream;     -   Step e): introducing at least one portion of the gas stream         resulting from step d) into a Joule-Thomson expansion means;     -   Step f): heating at least one portion of the expanded stream         resulting from step e) by introduction into the heat exchanger         used in step a) counter-current to the feed stream in order to         cool the latter.

According to other embodiments, a subject of the invention is also:

-   -   A process as defined above, characterized in that the heated         stream resulting from step f) is recycled by mixing with the         feed stream.     -   A process as defined above, characterized in that at least one         portion of the liquid stream resulting from step d) is         introduced into the heat exchanger used in step a)         counter-current to the feed stream,     -   A process as defined above, characterized in that at least one         portion of the liquid stream resulting from step b) is mixed         with said at least one portion of the liquid stream resulting         from step d) before being introduced into the heat exchanger         used in step a) counter-current to the feed stream.     -   A process as defined above, characterized in that at least one         portion of the methane-enriched permeate stream resulting from         step c) is heated by introduction into the heat exchanger used         in step a) counter-current to the feed stream in order to cool         the latter.     -   A process as defined above, characterized in that said at least         one portion of the permeate stream resulting from step d)         undergoes a Joule-Thomson expansion prior to the introduction         thereof into the heat exchanger,     -   A process as defined above, characterized in that at least one         portion of the liquid stream resulting from step d) is         introduced into a third phase separator vessel in order to         produce at least two phases, including a liquid stream and a gas         stream.     -   A process as defined above, characterized in that said gas         stream at the outlet of the third phase separator vessel is         mixed is heated by introduction into the heat exchanger used in         step a) counter feed stream in order to cool the latter. The         expression “feed stream” as used in the present patent         application relates to any composition containing hydrocarbons,         including at least methane.

The heat exchanger may be any heat exchanger, any unit or other arrangement suitable for allowing the passage of a certain number of streams, and thus allowing direct or indirect exchange of heat between one or more refrigerant fluid lines and one or more feed streams.

Preferably, the purified stream (liquid fraction of the residue) comprises at least 50 mol % of hydrocarbons other than methane.

The membrane separation unit used during step c) has a greater selectivity for methane than for hydrocarbons containing at least two carbon atoms, preferably containing at least three carbon atoms and operates in the presence of liquid. Methane or even hydrogen is found in the permeate stream at the outlet of the membrane unit while the hydrocarbons heavier than methane are on the residue (retentate) side, giving rise to a partial or complete condensation of the liquid residue stream rich in hydrocarbons comprising at least two carbon atoms.

The present invention consists of the combination of a membrane unit with partial or complete condensation on the residue (retentate) side and a heat exchanger between the feed gas cooled by the expanded gas fraction or the expanded liquid fraction of said residue in order to effectively separate methane from the heavier hydrocarbons. The lower temperature thus obtained for the feed stream makes it possible to increase the rate of formation of liquid hydrocarbons.

BRIEF DESCRIPTION OF THE DRAWING

An example of use of the present invention is illustrated in the FIGURE by the following example.

In the FIGURE, a natural gas feed stream 1 is introduced into a heat exchanger 2 at a temperature T1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Typically the feed stream 1 may contain methane, ethane, propane, hydrocarbons containing at least four carbon atoms, CO₂, aromatics, nitrogen, water, sulfur compounds (H₂S for example).

The feed stream 1 may be compressed via a compressor 24 for example, so that the pressure is sufficient for the correct implementation of the process according to the invention.

A partially condensed stream 3 leaves the heat exchanger 2 at a temperature T2 below T1.

The stream 3 is introduced into a phase separator vessel 4 from which a water-rich liquid stream 5′, a liquid stream 5 rich in hydrocarbons containing at least two carbon atoms and a methane-enriched gas stream 6 emerge. The stream 3 may have been expanded to a stream 3′, via a Joule Thomson valve 26 for example, before it enters the separator vessel 4.

The gas stream 6 is then introduced into a membrane separation unit 7 having a greater selectivity for methane than for hydrocarbons containing more than two carbon atoms and operating in the presence of formation of liquid on the residue (retentate) side. In this membrane unit 7, the stream is separated into a methane-enriched gaseous permeate stream 8, the pressure of which is lower than the pressure of the stream 6, and a partially condensed residue stream 9 enriched in at least one hydrocarbon containing more than two carbon atoms.

The stream 9 is introduced into a phase separator vessel 10. A liquid stream 11 rich in hydrocarbons containing at least two carbon atoms and a gas stream 12 emerge therefrom.

The gas stream 12 can then, at least in part, be heated 15 in the heat exchanger 2 to a temperature fairly close to T1 (i.e. to a temperature T4 strictly above T2 and at least between T2 and T1). The stream 12 is heated in the heat exchanger 2 in the counter direction to the feed stream 1 which, in itself, is cooled to the temperature T2.

The stream 15 can then optionally be mixed with the feed stream 1 in order to be recycled. This recycling may take place after passing through a dedicated compressor 25 depending on the requirements and operating conditions if a treated gas compressor 24 is not used.

Prior to entering the heat exchanger 2, the stream 12 is expanded 14 using a Joule-Thomson valve 13.

It is also possible to introduce the liquid streams 5 and 11, at least in part, independently or after having been mixed 17 and optionally expanded via a Joule Thomson valve 36, into the heat exchanger 2 in order to be heated 27 and partially (or even completely) vaporized and used to cool the feed stream 1.

A portion of the liquid stream 11 can be introduced into a phase separator vessel 21 after having been expanded 20 via a Joule Thomson valve 28. From this phase separator vessel 21, a liquid phase 22 enriched in heavy hydrocarbons and a gas phase 23 emerge.

The gas phase 23 and/or at least one portion 18 of the methane-enriched permeate stream 8 exiting the membrane unit 7 can be introduced (optionally after mixing), after an optional expansion 19, into the heat exchanger 2 in order to serve as a cold source for cooling the feed gas 1. This results in a stream 29 which will be able to serve, at least in part, as methane-enriched fuel 30 if need be. At least one other portion 31 of this stream 29 could be mixed again with the portion 32 of the permeate stream 8 which has not been sent to the heat exchanger 2.

It is also possible for a portion 33 of the gas stream 12 leaving the phase separator vessel 10 to be drawn off in order to be mixed with the stream 32 or with the stream 30.

This mixing may take place after expansions via Joule Thomson valves 34 and 35 for example.

It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. Thus, the present invention is not intended to be limited to the specific embodiments in the examples given above. 

The invention claimed is:
 1. A process for purifying a feed gas stream comprising methane and hydrocarbons containing at least two carbon atoms, comprising the following steps: Step a): cooling the feed gas stream in a heat exchanger; Step b): introducing the stream resulting from step a) into a first phase separator vessel in order to produce a liquid stream depleted in methane and enriched in hydrocarbons containing more than two carbon atoms and a gas stream; Step c): separating the gas stream resulting from step b) in a membrane permeation unit from which at least one methane-enriched gaseous permeate stream and one partially condensed residue stream enriched in hydrocarbons containing at least two carbon atoms exit; Step d): introducing the residue stream resulting from step c) into a second phase separator vessel in order to produce at least two phases including a liquid stream and a gas stream; Step e): introducing at least one portion of the gas stream resulting from step d) into a Joule-Thomson expansion means; Step f): heating at least one portion of the expanded stream resulting from step e) by introduction into the heat exchanger used in step a) counter-current to the feed gas stream in order to cool the latter.
 2. The process as claimed in claim 1, wherein the heated stream resulting from step f) is recycled by mixing with the feed gas stream.
 3. The process as claimed in claim 1, wherein at least one portion of the liquid stream resulting from step d) is introduced into the heat exchanger used in step a) counter-current to the feed gas stream.
 4. The process as claimed in claim 3, wherein at least one portion of the liquid stream resulting from step b) is mixed with said at least one portion of the liquid stream resulting from step d) before being introduced into the heat exchanger used in step a) counter-current to the feed gas stream.
 5. The process as claimed in claim 1, wherein at least one portion of the methane-enriched permeate stream resulting from step c) is heated by introduction into the heat exchanger used in step a) counter-current to the feed stream in order to cool the latter.
 6. The process as claimed in claim 5, wherein said at least one portion of the permeate stream resulting from step d) undergoes a Joule-Thomson expansion prior to the introduction thereof into the heat exchanger.
 7. The process as claimed in claim 1, wherein at least one portion of the liquid stream resulting from step d) is introduced into a third phase separator vessel in order to produce at least two phases, including a liquid stream and a gas stream.
 8. The process as claimed in claim 7, wherein said gas stream at the outlet of the third phase separator vessel is mixed with the permeate stream resulting from step c).
 9. The process as claimed in claim 7, wherein the gas stream at the outlet of the third phase separator vessel is heated by introduction into the heat exchanger used in step a) counter-current to the feed stream in order to cool the latter. 